Copper-Clad Steel Ground Rod Manufacturing Process

When using copper-clad steel ground rods, it is necessary to understand the manufacturing process and the scope of use in detail in order to better play its greatest role. Now we will briefly introduce the manufacturing process requirements and application scope of the copper-clad steel ground rod.
Copper-clad steel ground rods, copper-plated pen direct ground electrodes, grounded horizontal copper-plated round steel, flat steel wire lugs and lead ground copper-plated round steel are all selected for anti-corrosion new welding technology exothermic welding. All copper-clad steel ground rods must be copper-plated with an electroplating process, and the continuous casting copper-clad steel process is completed. The copper layer thickness is not less than 0.254mm. The flux used for exothermic welding must support an integrated sealing flux, and an electronic ignition method is used to ignite The distance is not less than 1.5m, and it has passed UL467 certification. The scope of application of copper clad steel ground rod:

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Copper-clad steel ground rods entered my country in the s, and have successively been recognized by Sinopec, PetroChina, and electric power companies, and have gradually been promoted and used. In recent years, my country's petrochemical, electric power, communications and other system enterprises have been increasingly troubled by grounding devices. The reliability, stability and service life of grounding devices have attracted widespread attention. Therefore, electroformed copper clad steel materials have replaced traditional materials. For hot-dip galvanized steel, the use of hot-melt welding to replace the traditional electric welding connection to build grounding devices has gradually become widespread. The thickness of the copper coating of the copper-clad steel ground rod can be measured by an electronic thickness micrometer at a regular number of points at each point, and the thickness must be at least 0.250mm. This thickness ensures that the bottom of the thread produced after copper plating is completely covered by copper.
The thickness of the copper plating of the ground rod is 0.250mm, which ensures that it can be used underground for 30 years. The plasticity of the coating-the rod is bent 180 degrees and then tested, it must not show cracks and peeling off, and the adhesion of the copper coating-when the ground rod is driven into the ground, it should be tested whether the coating tends to separate. The specific method is: clamp the ground rod to be tested between the vise, the distance between the jaws is equal to the diameter of the rod minus 1.2mm. When the rod is squeezed, the vise will cut off the rod in contact with it Plating layer, and the remaining part of the surface of the plating layer will not fall off, such a plating layer can ensure that the ground rod can be threaded after copper plating.
The thickness of the copper layer of the copper-clad steel grounding electrode is as high as 0.254mm, which is much higher than the standard. It can also be customized according to customer requirements. The tensile strength is as high as 600 Newtons/square millimeter, and the corrosion resistance is strong. No matter it is natural corrosion after deep buried underground It is still an electrochemical reaction, which is extremely protective and has good electrical properties; the excellent conductivity of the surface copper material makes its own resistance value far lower than conventional materials. The connection is firm and reliable; the special connection is used for receiving or exothermic welding, the joint is firm and the stability is good.
Sichuan Sunlight provides customers with high-quality copper-clad steel ground rods, and we use advanced manufacturing techniques. The product has a wide range of applications and high product quality. For more detailed information about copper clad steel ground rods, please contact us.
Tag: copper-clad steel ground rod, copper-clad steel ground rod manufacturing process, copper-clad steel ground rod application scope

An electrical conductor is a material that allows electricity to flow through it. However choosing between &#;copper-clad steel conductors&#; and &#;pure copper conductors&#; for lightning protection can be confusing, as both serve similar purposes. But, selecting the wrong one can make a significant difference.

Conductors can generally be classified by the metals they are made from, which depends on the intended purpose. In this blog, we will discuss two widely used conductors: copper-clad steel conductors and pure copper conductors. Additionally, there are various other conductors available in the market, including:

1. 1. Copper-Clad Steel
   2. Copper
   3. High Strength Alloys
   4. Stainless Steel
   5. Bare Copper
   6. Tinned Copper
   7. Silver Coated Copper
   8. Nickel-Coated Copper

A) Copper-Clad Steel Conductors

Copper-clad steel conductors, also known as copper-covered steel conductors, are composite material conductors. They consist of a uniform low, medium, or high carbon steel core surrounded by a thick layer of copper. The inner carbon steel core gives the conductor its high tensile strength, while the outer copper cladding provides electrical conductivity. In simple terms, this conductor has a steel core that grants it strength and a copper layer on the outside that ensures electrical conductivity.

Manufacturing of Copper-Clad Steel Conductors

The production of copper-clad steel conductors begins with a mild steel conductor, which undergoes a series of processes to enhance its physical properties and surface quality. Initially, the conductor is peeled to remove imperfections, straightened and turned for uniformity, and finally polished to achieve a smooth finish.

Next, the conductor enters the electroplating stage, where it is coated with oxygen-free copper at high temperatures, approximately 25-30 degrees Celsius. Following this, the conductor is subjected to hot-dipping in an oxygen-free copper-clad steel bath, maintained at approximately 45-50 degrees Celsius, ensuring a uniform coating.

After the hot-dipping process, the conductor is immediately cooled with water to strengthen the copper layer. To further enhance the conductor, it undergoes cold rolling, allowing for customization of shape and size according to specific needs. If necessary, the conductor then undergoes annealing&#;a heat treatment in nitrogen gas to improve its ductility and relieve internal stresses. This is the process by which a copper-clad steel conductor is manufactured.

Applications Copper-Clad Steel Conductors

Copper-clad steel conductors are widely used in grounding, i.e. connection of earthing rods to metallic structures, plates, and grid meshes, in power installations, substations, and for lightning arresters. Copper-clad steel conductors are also used for power transmission and radio frequency (RF) transmission lines.

Advantages of Copper-Clad Steel Conductors

• During the process of bonding copper and steel, the coating is created on the Copper-clad steel conductors to protect the wire from breakage and corrosion. This also gives them about 43% higher break-load capacity than Pure Copper.
• Due to its corrosion resistance, the wire has lasting durability and longevity, reducing maintenance costs.
• Copper-clad steel conductors are about 10% lighter than Copper ones, therefore, their transportation costs are less and they are easier to handle during their installation and maintenance.
• In Copper-clad steel conductors, the outer copper layer has a lower impedance than that of the inner steel core. So when these conductors are used in Radio Frequency transmission lines, the &#;skin effect&#; at high frequency encounters low impedance in the copper cladding, which is equivalent to that of a solid copper conductor.
• The tensile strength of Copper-clad steel conductors is greater than that of Pure Copper. Therefore with Copper-clad steel, the span lengths can be greater as compared to the span lengths achieved with pure copper ones.
• Copper-clad steel conductors can be used in coaxial cables thereby allowing higher impedance and smaller cable diameter than by using  Copper Conductors of similar strength.
• In Copper-clad steel conductors, the amount of the more expensive copper is lesser than the amount of steel, and the two metals (i.e. copper and steel) cannot be separated easily. Therefore, this has little scrap value and discourages theft. Copper-clad steel conductors exhibit lower impedance to the ground as compared to pure copper, thus providing better protection to lines and equipment.

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B) Copper Conductors

Pure copper conductors are made a bit differently. They are produced by pushing pure copper ingots through an extrusion machine. This machine forces the copper through several moulds in a row to achieve the right size and shape for the conductor.

Where are they used?

They are used in power generation, power transmission, power distribution, telecommunications, electronics circuitry, and several types of electrical equipment. They are found to be ideal in permanent applications where the conductors, cables, or wires are unlikely to be replaced or changed (e.g. concealed wiring inside walls). Also, Copper Conductors in the form of cables find ideal use in signal transmission over long distances since minimal current is required to drive the signals on account of the high conductivity of copper (conductors). They excel in transmitting high levels of data over these distances &#; and minimal current is necessary to push signals all the way through.

 Advantages of Copper Conductors

• They possess very high conductivity, much higher than any of the other conventional conductors.
• Copper exhibits durability and flexibility, which are the two big benefits of using them. The conductors can be easily bent back and forth, and are easy to form and shape. Solid copper as a conductor is usually preferred for longer cables.
• These conductors have better bend radius and can retain better signal strengths over long distances.
• They are most suited for permanent applications, such as concealed cabling inside walls, and other applications where the cables are not likely to be changed.
• The expected lifespan of copper is 100 + years.

Which conductor do you need?

Your choice should match your needs. For Earthing and Lightning Protection, copper-clad steel is the more cost-effective option. To illustrate the cost difference, if 1 meter of Copper Bonded Steel Conductor costs you X amount, the same length of Pure Copper will cost about 3 to 4X.

However, both conductors do an excellent job of protecting your building from lightning strikes. They safely channel it to the ground without causing dangerous temperature increases, that could damage your structure.

We hope you now have a clear idea about all the 2 conductors. At Axis, we have a team of 40+ engineers who are here to help you in designing, installing and testing your Grounding and lightning Protection Systems. Our products have been used in substations, data centres, factories and even in everyday residential and commercial buildings.

Thank you for reading the blog, Axis is a leading manufacturer and supplier of AB Cable Accessories and other Electrical Components to over 80+ Countries. To get a quote or to talk to our industry expert visit our contact us section. You can also watch our videos by our experts &#; click here.

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